Insulation with reactive flaps

ABSTRACT

Insulation comprises a plurality of reactive flaps that react to one or more external stimuli, e.g., humidity. The flaps are made up of a fiber mixture that includes: 20-80 wt % reactive bicomponent fibers that are reactive to an external stimulus, and have a first configuration in an unactivated state and a second configuration in an activated state, and wherein the bicomponent fibers can reversibly transform between the unactivated and activated states; 5-40 wt % synthetic binder fibers having a denier of 1.5 to 4.0 denier; 0-75 wt % of a first population of synthetic fibers, being synthetic polymeric fibers having a denier of less than 2.0 denier; and 0-75 wt % of a second population of synthetic fibers, being synthetic polymeric fibers having a denier of 4.0 to 10.0 denier. Related articles and methods are also provided.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.62/448,182, filed Jan. 19, 2017, the disclosure of which is herebyincorporated herein in its entirety.

FIELD OF THE INVENTION

The present invention generally relates to insulation, to articlescomprising the insulation, and to methods of making the insulation.

BACKGROUND OF THE INVENTION

Often, the environment within which an individual finds oneself canchange quickly. For example, during periods of exercise, and even whengoing about daily activities, one can quickly transition from a state ofrelative inactivity to high activity. Similarly, people often move fromcontrolled indoor climates to drastically different outdoor climates.Moreover, climate change has resulted in weather conditions that can beunpredictable and that can vary significantly, even within a short timeperiod within a single day. In view of the various humidity ranges andtemperature fluctuations that people regularly experience, it isdesirable to have adaptive articles (e.g., of clothing and outerwear)that can adjust to improve wearer/user comfort.

Thus, a need exists for new insulation and articles that are readilyadaptable to an external stimulus such as temperature and/or humidity.

While certain aspects of conventional technologies are discussed tofacilitate disclosure of the invention, Applicant in no way disclaimsthese technical aspects, and it is contemplated that the claimedinvention may encompass one or more conventional technical aspects.

In this specification, where a document, act or item of knowledge isreferred to or discussed, this reference or discussion is not anadmission that the document, act or item of knowledge or any combinationthereof was, at the priority date, publicly available, known to thepublic, part of common general knowledge, or otherwise constitutes priorart under the applicable statutory provisions; or is known to berelevant to an attempt to solve any problem with which thisspecification is concerned.

SUMMARY OF THE INVENTION

Briefly, embodiments of the present invention satisfy the need forinsulation and articles that are readily adaptable to an externalstimulus such as temperature and/or humidity.

The present invention may address one or more of the problems anddeficiencies of the art discussed above. However, it is contemplatedthat the invention may prove useful in addressing other problems anddeficiencies in a number of technical areas. Therefore, the claimedinvention should not necessarily be construed as limited to addressingany of the particular problems or deficiencies discussed herein.

In a first aspect, the invention provides insulation having a pluralityof slits therein that form a plurality of reactive flaps in theinsulation, such that the insulation comprises the flaps and also anon-flap portion, wherein said reactive flaps comprise a flap fibermixture that comprises:

-   -   20-80 wt % bicomponent fibers having a core and a sheath, said        fibers having a denier of 2.0 to 8.0 denier, and a staple cut        length of 38 to 105 mm, wherein said bicomponent fibers are        reactive to an external stimulus, and have a first configuration        in an unactivated state and a second configuration in an        activated state, and wherein the bicomponent fibers can        reversibly transform between the unactivated and activated        states;    -   5-40 wt % synthetic binder fibers having a denier of 1.5 to 4.0        denier and a staple cut length of 38 to 105 mm;    -   0-75 wt % of a first population of synthetic fibers, being        synthetic polymeric fibers having a denier of less than 2.0        denier and a staple cut length of 38 to 105 mm; and    -   0-75 wt % of a second population of synthetic fibers, being        synthetic polymeric fibers having a denier of 4.0 to 10.0 denier        and a staple cut length of 38 to 105 mm.

In a second aspect, the invention provides an article comprising theinventive insulation according to the first aspect of the invention.

In a third aspect, the invention provides a method of making theinventive insulation according to the first aspect of the invention,said method comprising:

-   -   forming an intermediate insulation from a fiber mixture, said        intermediate insulation comprising a plurality of flap areas        that comprise the flap fiber mixture discussed in accordance        with the first aspect of the invention;    -   heating the intermediate insulation in excess of the bonding        temperature of the binder fibers in the flap fiber mixture; and    -   forming a plurality of slits in the intermediate insulation,        thereby creating a plurality of reactive flaps.

Certain embodiments of the presently-disclosed insulation, articlescomprising the insulation, and methods of making the insulation haveseveral features, no single one of which is solely responsible for theirdesirable attributes. Without limiting the scope of the insulation,articles, and methods as defined by the claims that follow, their moreprominent features will now be discussed briefly. After considering thisdiscussion, and particularly after reading the section of thisspecification entitled “Detailed Description of the Invention,” one willunderstand how the features of the various embodiments disclosed hereinprovide a number of advantages over the current state of the art. Forexample, embodiments of the insulation provide reactive insulation thatquickly adapts in order to maximize user/wearer comfort. Embodiments ofthe insulation can be used to make various articles, including clothing,outerwear, footwear, bedding, etc.

These and other features and advantages of this invention will becomeapparent from the following detailed description of the various aspectsof the invention taken in conjunction with the appended claims and theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will hereinafter be described in conjunction withthe following drawing figures, which are not necessarily drawn to scale,and wherein like numerals denote like elements, and:

FIG. 1 is a top-view photograph of an embodiment 10 of the inventiveinsulation.

FIG. 2 is a simplified rendering of the top-view photograph FIG. 1, withreactive flaps 4 shown in black shading.

FIGS. 3A and 3B depict an embodiment of a bicomponent fiber used incertain embodiments of the inventive insulation in its unactivated stateand activated state, respectively.

FIGS. 4A-F depict non-limiting examples of cross-sections thatbicomponent fibers used in certain embodiments of the invention canhave.

DETAILED DESCRIPTION OF THE INVENTION

Aspects of the present invention and certain features, advantages, anddetails thereof are explained more fully below with reference to thenon-limiting embodiments illustrated in the accompanying drawings.Descriptions of well-known materials, fabrication tools, processingtechniques, etc., are omitted so as to not unnecessarily obscure theinvention in detail. It should be understood, however, that the detaileddescription and the specific example(s), while indicating embodiments ofthe invention, are given by way of illustration only, and are not by wayof limitation. Various substitutions, modifications, additions and/orarrangements within the spirit and/or scope of the underlying inventiveconcepts will be apparent to those skilled in the art from thisdisclosure.

In a first aspect, the invention provides insulation having a pluralityof slits therein that form a plurality of reactive flaps in theinsulation, such that the insulation comprises the flaps and also anon-flap portion, wherein said reactive flaps comprise a flap fibermixture that comprises:

-   -   20-80 wt % bicomponent fibers having a core and a sheath, said        fibers having a denier of 2.0 to 8.0 denier, and a staple cut        length of 38 to 105 mm, wherein said bicomponent fibers are        reactive to an external stimulus, and have a first configuration        in an unactivated state and a second configuration in an        activated state, and wherein the bicomponent fibers can        reversibly transform between the unactivated and activated        states;    -   5-40 wt % synthetic binder fibers having a denier of 1.5 to 4.0        denier and a staple cut length of 38 to 105 mm;    -   0-75 wt % of a first population of synthetic fibers, being        synthetic polymeric fibers having a denier of less than 2.0        denier and a staple cut length of 38 to 105 mm; and    -   0-75 wt % of a second population of synthetic fibers, being        synthetic polymeric fibers having a denier of 4.0 to 10.0 denier        and a staple cut length of 38 to 105 mm.

Denier is a unit of measure defined as the weight in grams of 9000meters of a fiber or yarn. It is a common way to specify the weight (orsize) of the fiber or yarn. For example, polyester fibers that are 1.0denier typically have a diameter of approximately 10 micrometers.Micro-denier fibers are those having a denier of 1.0 or less, whilemacro-denier fibers have a denier greater than 1.0.

In some embodiments, the components of the flap fiber mixture arehomogenously mixed, meaning, the mixture has a substantially uniform(i.e., 90-100% uniform, e.g., greater than or equal to 90, 91, 92, 93,94, 95, 96, 97, 98, or 99% uniform) composition.

In various embodiments of the invention, the reactive flaps shrink andexpand when exposed to an external stimulus (e.g., humidity). Forexample, in some embodiments, the flaps shrink when exposed torelatively higher humidity levels, and expand when exposed to relativelylower humidity levels respectively. This reactive functionalityessentially results in insulation embodiments' ability to open/closeflaps based on changing humidity levels. For example, when used in,e.g., certain embodiments of an article of clothing or outwear, duringperiods of general inactivity, the flaps will remain closed (here, thebicomponent fibers are considered to be in an unactivated state),whereas, during periods of activity where moisture is generated leadingto a humidity increase, the flaps will shrink (to the bicomponentfibers' activated state), thereby effectively venting the insulation,and providing a more breathable and/or less insulative article.

FIG. 1 is a top-view photograph of an embodiment 10 of the inventiveinsulation. As can be seen, insulation 10 comprises a plurality of slits2. In the depicted embodiment, each slit 2 forms a flap (also referredto herein as a “reactive flap”) 4, and the insulation 10 comprises aplurality of flaps 4. In addition to the flaps, insulation 10additionally comprises at least one non-flap portion 6. As can be seen,in the depicted embodiment of insulation 10, non-flap portion 6 is acontinuous portion of the insulation 10, having slits 2 therein thatform a plurality of reactive flaps 4 in the insulation. In insulation10, reactive flaps 4 comprise a flap fiber mixture as described herein,and non-flap portion 6 comprises the same flap fiber mixture.

FIG. 2 is a simplified/marked-up version of the top-view photograph ofFIG. 1. For ease of visualization, in FIG. 2, slits 2 are shown inwhite. The reactive flaps 4 defined by slits 2 are shown in black, andthe non-flap portion 6 is shown in light grey.

While the slits 2 in insulation 10 are C-shaped slits formingsemicircle-like flaps 4, the insulation can comprise slits of anydesired shape. Persons having ordinary skill in the art will recognizethat there are a variety of shapes that the reactive flaps can take, asthe shape of the slits and flaps are generally non-limiting relative tothe inventive concept. Indeed, in view of the disclosure herein, personshaving ordinary skill in the art will understand that the flaps arereactive by nature of the composition of the flap fiber mixture, andthey will readily be able to ascertain different shapes/configurationsthat slits and flaps can assume. Generally speaking, the flaps areattached to the insulation at one side. In some non-limiting examples,the slits are made so as to form flaps that are semi-circular (orotherwise circular in shape, but remain attached to the insulation),oval, square, rectangle, or triangle-shaped.

The size and frequency of the flaps can be altered depending on theamount of desired potential reactivity to the external stimulus (e.g.,humidity). In some non-limiting embodiments, the flaps have a maximumdimension of 2.5 cm (i.e., when the size of a flap is measured in everytwo-dimension direction of the shape of the flap formed by the slit, themaximum measurement is 2.5 cm). For example, in some embodiments, theflaps have a maximum dimension of 0.5 cm to 2.5 cm (e.g., 0.5, 0.6, 0.7,0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1,2.2, 2.3, 2.4, or 2.5 cm), including any and all ranges and subrangestherein. In some embodiments, the flaps have a maximum dimension of 0.5to 2 cm, including any and all ranges and subranges therein (e.g., 0.75to 1.25 cm).

The frequency of the flaps in the insulation can be varied as desired toincrease/decrease the amount of open space in the insulation when it issubjected to an external stimulus (e.g., high humidity levels). Forexample, in some embodiments, the flaps make up 5 to 80% of the surfacearea of the insulation (e.g., 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16,17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34,35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52,53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70,71, 72, 73, 74, 75, 76, 77, 78, 79, or 80%), including any and allranges and subranges therein. In some embodiments, the non-flapportion(s) of the insulation makes up 20 to 95% of the surface area ofthe insulation (e.g., 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31,32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49,50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67,68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85,86, 87, 88, 89, 90, 91, 92, 93, 94, or 95%), including any and allranges and subranges therein. In FIG. 1, the area of the entire visiblesurface of insulation 10 constitutes the surface area of saidinsulation. In some embodiments the flaps are spaced 1.5 to 5 cm fromone another, including any and all ranges and subranges therein (e.g.,spaced 2 to 3 cm apart).

The flaps comprise a flap fiber mixture. The flap fiber mixturecomprises:

-   -   20-80 wt % bicomponent fibers having a core and a sheath, said        fibers having a denier of 2.0 to 8.0 denier, and a staple cut        length of 38 to 105 mm, wherein said bicomponent fibers are        reactive to an external stimulus, and have a first configuration        in an unactivated state and a second configuration in an        activated state, and wherein the bicomponent fibers can        reversibly transform between the unactivated and activated        states;    -   5-40 wt % synthetic binder fibers having a denier of 1.5 to 4.0        denier and a staple cut length of 38 to 105 mm;    -   0-75 wt % of a first population of synthetic fibers, being        synthetic polymeric fibers having a denier of less than 2.0        denier and a staple cut length of 38 to 105 mm; and    -   0-75 wt % of a second population of synthetic fibers, being        synthetic polymeric fibers having a denier of 4.0 to 10.0 denier        and a staple cut length of 38 to 105 mm.

As mentioned above, 20-80 wt % of the flap fiber mixture is made up ofthe reactive bicomponent fibers.

The bicomponent fibers are reactive to an external stimulus. In someembodiments, the external stimulus is humidity, pH, temperature, light,electrical current, force field, or microbes.

Some materials that are reactive to one or more external stimuli arediscussed, for example, in International Application Publication No.WO/2009106785 A1.

The bicomponent fibers have an unactivated state. While in theunactivated state, the bicomponent fibers have a first configuration.When exposed to the intended external stimulus, the bicomponent fiberstransform to a second configuration (activated state). When no longerexposed to the external stimulus, the bicomponent fibers transform backto the first configuration in the unactivated state. The bicomponentfibers go back and forth between activated and unactivated states,depending on whether or not they are exposed to the external stimulus.Therefore, the bicomponent fibers can reversibly transform between theunactivated and activated states. In some embodiments, upon exposure toan intended external stimulus, the bicomponent fibers reversiblytransform from unactivated to activated state in less than or equal to15 minutes (e.g., less than or equal to 15, 14, 13, 12, 11, 10, 9, 8, 7,6, 5, 4, 3, 2, or 1 minutes). In some embodiments, upon removal of theintended external stimulus, the bicomponent fibers reversibly transformfrom activated to unactivated state in less than or equal to 15 minutes(e.g., less than or equal to 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4,3, 2, or 1 minutes).

FIGS. 3A and 3B depict an embodiment of a bicomponent fiber 20 used incertain embodiments of the inventive insulation in its unactivated stateand activated state, respectively. Bicomponent fiber 20 has a helix (akahelical) shape/crimp. A helix may be described as a three-dimensionalcurve around an axis. The pitch of a helix is the length of one completeturn measured along the axis of the helix. A circular helix has aconstant curvature and constant torsion.

When in a dry environment, fiber embodiment 20 is in the unactivatedstate shown in FIG. 3A. When exposed to an intended external stimulus,such as increased humidity, fiber 20 transforms to the activated stateshown in FIG. 3B, wherein the crimp of fiber 20 increases, such that thenumber of bends per length increases and the radius of the bends and/orthe pitch decreases, that is, the helix becomes tighter, the radius andpitch of the helix decrease, and the fiber's helical configurationbecomes more compact.

Persons having ordinary skill in the art will understand that certainembodiments of the bicomponent fibers used herein (e.g., the bicomponentfiber 20 of FIGS. 3A and 3B having a helix structure) have a structurethat is caused by deliberate selection of the fiber's components. Forexample, in some embodiments (e.g., certain embodiments where thebicomponent fibers are intended to be reactive to humidity as externalstimulus), one of the core and sheath of the bicomponent fiber isnon-hygroscopic, and the other is hygroscopic. For example, in someembodiments, the core comprises a non-hygroscopic material and thesheath comprises a hygroscopic material. In some embodiments, thehygroscopic material is selected to have less thermal shrinkage and tobe less stiff than the non-hygroscopic material. In some embodiments,when, e.g., co-extruded then heat shrunk, the hygroscopic material wantsto elongate. However, this is restricted by the non-hygroscopicmaterial, thereby resulting in a helix structure. On exposure tohumidity, the hygroscopic material wants to further elongate. Again,this action is resisted by the non-hygroscopic material and the stiffernon-hygroscopic component causes the helix angle to tighten. Thisresults in the activated configuration shown in FIG. 3B. Compared withthe fiber 20 in relatively dry conditions (FIG. 3A), in FIG. 3B, thewidth a is reduced and the length b is reduced. On removal of theexternal stimulus (e.g., humidity), fiber 20 returns to its unactivatedconfiguration shown in FIG. 3A. In some embodiments, the length b may bereduced by 5 to 40% (e.g., 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16,17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34,35, 36, 37, 38, 39, or 40%), including any and all ranges and subrangestherein (e.g., 10 to 20%), and the width a may be reduced by 2 to 30%(e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19,20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30%), including any and allranges and subranges therein (e.g., 3 to 15%), in 100% humid conditionsas compared with dry conditions.

In some embodiments, the non-hygroscopic material comprisesnon-hygroscopic polyethylene, polypropylene, polystyrene, and/orpolyvinyl chloride (PVC).

In some embodiments, the hygroscopic material comprises nylon,acrylonitrile butadiene styrene (ABS), an acrylic resin, polyurethane,polycarbonate, polyethylene terephthalate (PET), and/or polybutyleneterephthalate (PBT).

In particular embodiments, the bicomponent fibers comprise nylon andpolypropylene. For example, in some embodiments, the core comprisespolypropylene and the sheath comprises nylon.

In some embodiments, the bicomponent fibers comprise 20 to 50 weight %(wt %) core material (e.g., 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30,31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48,49, or 50 wt %), including any and all ranges and subranges therein(e.g., 20 to 40 wt %, 25 to 35 wt %, etc.).

In some embodiments, the bicomponent fibers comprise a majority(i.e., >50 wt %) of sheath material. For example, in some embodiments,the bicomponent fibers comprise 50 to 80 wt % sheath material (e.g., 50,51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68,69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, or 80 wt %), including anyand all ranges and subranges therein (e.g., 60 to 80 wt %, 65 to 75 wt%, etc.).

In some embodiments, the bicomponent fibers have a helix firstconfiguration and the second configuration is a helix with relativelydecreased radius and/or pitch as compared to the first configuration.

In some embodiments, the bicomponent fibers' second configuration hasincreased twist as compared to the first configuration. In someembodiments, the bicomponent fiber has twist in both the first andsecond configurations.

In some embodiments, twist is imparted upon the shape of the bicomponentfibers by deliberate selection of the different materials that make upthe bicomponent fibers. Embodiments of the bicomponent fibers containtwo or more components, the components being made of differentmaterials. The components are usually combined during the manufacture ofthe fibers, and may be combined in any ratio. Known manufacturingprocesses enable various bicomponent cross-sections to be achieved.

FIGS. 4A-F depict non-limiting examples of cross-sections thatbicomponent fiber 20′ used in certain embodiments of the invention canhave. In FIG. 4A, the core 42 and sheath 44 are in a 50:50 ratio and arein a side-by-side arrangement. As used herein, the term “core” refers toa foundational part of the bicomponent fiber that is distinct from thesheath portion. In various embodiments, the core may be at the center,innermost part of the bicomponent fiber. However, in other embodiments,the core may be off-centered, or present at at least a portion of aperipheral surface of the bicomponent fiber. In FIG. 4B the core 42 andsheath 44 are in an unequal radio and are in a side-by-side arrangement.Further, the interface between the core 42 and sheath 44 is not planar.In FIGS. 4C-4F, the core 42 and sheath 44 are in a concentricarrangement, where core 42 forms an interior portion of bicomponentfiber 20′ and is surrounded by sheath 44. In the non-limitingembodiments shown in FIGS. 4A to 4E, the core 42 is asymmetricallyplaced relative to the sheath 44 (i.e., the core 42 is symmetricallyoff-set within the bicomponent fiber 20′). In FIGS. 4C-4F, the core 42is off-center (i.e., displaced from a center point or axis of the fiber)but still fully surrounded by the sheath 44. FIG. 4E shows a tri-lobalfiber 20′. The arrangements shown in FIGS. 4C-4F are also known as “seaisland” configurations. Persons having ordinary skill in the art willunderstand that these are arrangements that are not limited and mayinclude further components or additional “islands”.

In some embodiments, the bicomponent fibers are straight or relativelystraight in the first configuration, then become crimped or twisted uponexposure to the external stimulus (e.g., humidity).

The bicomponent fibers have a denier of 2.0 to 8.0 denier (e.g., 2.0,2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4,3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8,4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2,6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6,7.7, 7.8, 7.9, or 8.0 denier), including any and all ranges andsubranges therein. For example, in some embodiments, the bicomponentfibers have a denier of 2.0 to 7.0 denier, 2.0 to 4.5 denier, 2.0 to 3.0denier, etc.

The bicomponent fibers are staple fibers (i.e., fibers having astandardized length) having a length of 38 to 105 mm (e.g., 38, 39, 40,41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58,59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76,77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94,95, 96, 97, 98, 99, 100, 101, 102, 103, 104, or 105 mm), including anyand all ranges and subranges therein.

In some embodiments, the bicomponent fibers comprise the active fiber asdescribed in International Application Publication No. WO/2013186528 A1.

In some embodiments, the bicomponent fibers comprise commerciallyavailable INOTEK fibers available from MMT Textiles Limited.

In addition to the bicomponent fibers, the flap fiber mixture alsocomprises 0 to 75 wt % of a first population of synthetic fibers, and 0to 75 wt % of a second population of synthetic fibers.

Persons having ordinary skill in the art are readily familiar with manysynthetic fibers, and it is well within their purview to selectappropriate synthetic fiber for use in the first and/or secondpopulations of synthetic fibers depending on desired properties of theinsulation being made and/or the article within which it is intended tobe employed. Embodiments of the inventive insulation can comprise anysynthetic fiber known in the art as being conducive to the preparationof textile materials. In some embodiments, nonexclusive synthetic fibersthat may be used in the invention (e.g., comprised within the firstand/or second populations) are selected from nylon, polyester,polypropylene, polylactic acid (PLA), poly(butyl acrylate) (PBA),polyamide, acrylic, acetate, polyolefin, nylon, rayon, lyocell, aramid,spandex, viscose, and modal fibers, and combinations thereof. Inparticular embodiments, synthetic fibers comprise polyester fibers. Forexample, in some embodiments, the polyester is selected frompoly(ethylene terephthalate), poly(hexahydro-p-xylylene terephthalate),poly(butylene terephthalate), poly-1,4-cyclohexelyne dimethylene (PCDT)and terephthalate copolyesters in which at least 85 mole percent of theester units are ethylene terephthalate or hexahydro-p-xylyleneterephthalate units. In a particular embodiment, the polyester ispolyethylene terephthalate. In some embodiments, the synthetic fiberscomprise virgin fibers. In some embodiments, the synthetic fiberscomprise recycled fibers (e.g., recycled polyester fibers).

The flap fiber mixture of the inventive insulation contains 0 to 75 wt %of the first population of synthetic fibers (e.g., 0, 1, 2, 3, 4, 5, 6,7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25,26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43,44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61,62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, or 75 wt %),including any and all ranges and subranges therein. The fibers of thefirst population have a denier of less than 2.0 denier (for example, 0.4to 1.9 denier, e.g., 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3,1.4, 1.5, 1.6, 1.7, 1.8, or 1.9 denier, including any and all ranges andsubranges therein). The fibers of the first population have a staple cutlength of 38 to 105 mm (e.g., 38, 39, 40, 41, 42, 43, 44, 45, 46, 47,48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65,66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83,84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100,101, 102, 103, 104, or 105 mm), including any and all ranges andsubranges therein.

The flap fiber mixture of the inventive insulation contains 0 to 75 wt %of the second population of synthetic fibers (e.g., 0, 1, 2, 3, 4, 5, 6,7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25,26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43,44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61,62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, or 75 wt %),including any and all ranges and subranges therein. The fibers of thesecond population have a denier of 4.0 to 10.0 denier (e.g., 4.0, 4.1,4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5,5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9,7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3,8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7,9.8, 9.9, 10.0), including any and all ranges and subranges therein. Thefibers of the second population have a staple cut length of 38 to 105 mm(e.g., 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53,54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71,72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89,90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, or 105mm), including any and all ranges and subranges therein.

The material of the fibers of the first and second populations areindependently selected. In some embodiments, the fibers of the firstpopulation are the same material as the fibers of the second population.In other embodiments, the fibers of the first population are a differentmaterial than the fibers of the second population. In particularembodiments, the fibers of the first and second populations comprisepolyethylene.

In some embodiments, the flap fiber mixture comprises siliconizedfibers. The term “siliconized” means that the fiber is coated with asilicon-comprising composition (e.g., a silicone). Siliconizationtechniques are well known in the art, and are described, e.g., in U.S.Pat. No. 3,454,422. The silicon-comprising composition may be appliedusing any method known in the art, e.g., spraying, mixing, dipping,padding, etc. The silicon-comprising (e.g., silicone) composition, whichmay include an organosiloxane or polysiloxane, bonds to an exteriorportion of the fiber. In some embodiments, the silicone coating is apolysiloxane such as a methylhydrogenpolysiloxane, modifiedmethylhydrogenpolysiloxane, polydimethylsiloxane, or amino modifieddimethylpolysiloxane. As is known in the art, the silicon-comprisingcomposition may be applied directly to the fiber, or may be diluted witha solvent as a solution or emulsion, e.g. an aqueous emulsion of apolysiloxane, prior to application. Following treatment, the coating maybe dried and/or cured. As is known in the art, a catalyst may be used toaccelerate the curing of the silicon-comprising composition (e.g.,polysiloxane containing Si—H bonds) and, for convenience, may be addedto a silicon-comprising composition emulsion, with the resultantcombination being used to treat the synthetic fiber. Suitable catalystsinclude iron, cobalt, manganese, lead, zinc, and tin salts of carboxylicacids such as acetates, octanoates, naphthenates and oleates. In someembodiments, following siliconization, the fiber may be dried to removeresidual solvent and then optionally heated to between 65° and 200° C.to cure.

In some embodiments, the synthetic fibers of the first population arenon-siliconized fibers. In some embodiments, the synthetic fibers of thefirst population are siliconized fibers. In some embodiments, thesynthetic fibers of the first population comprise both siliconized andnon-siliconized fibers.

In some embodiments, the synthetic fibers of the second population arenon-siliconized fibers. In some embodiments, the synthetic fibers of thesecond population are siliconized fibers. In some embodiments, thesynthetic fibers of the second population comprise both siliconized andnon-siliconized fibers.

In some embodiments, the synthetic fibers of both the first and secondpopulations comprise non-siliconized fibers. In some embodiments, thesynthetic fibers of both the first and second populations comprisesiliconized fibers. In some embodiments, the synthetic fibers of boththe first and second populations comprise both siliconized andnon-siliconized fibers.

In some embodiments, 0 to 100 wt % of each of the first and second fiberpopulations are siliconized fibers (with the respective weightpercentages of each population being selected independently), forexample, 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17,18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35,36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53,54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71,72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89,90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100 wt %, including any andall ranges and subranges therein (e.g., 20 to 95 wt %, 25 to 90 wt %, 30to 90 wt %, 40 to 85 wt %, 51 to 90 wt %, etc.).

Generally speaking, fibers, such as those of the first and secondpopulations, may be crimped or uncrimped. Various crimps, includingspiral and standard (e.g., planar) crimp, are known in the art. Unlessotherwise specified, fiber lengths, throughout this application, arepre-crimp measurements (i.e., the length measurement of a fiber beforeit is crimped, if said fiber has a crimp).

In some embodiments, the fibers of the first population of syntheticfibers comprise fibers having a standard or spring-like (e.g., helical)crimp. In particular embodiments, the fibers of the first population ofsynthetic fibers comprise fibers having a standard crimp.

In some embodiments, the fibers of the second population of syntheticfibers comprise fibers having a standard or spring-like (e.g., helical)crimp. In particular embodiments, the fibers of the second population ofsynthetic fibers comprise fibers having a spring-like (e.g., helical)crimp.

Durable water repellant (DWR) treatments are well known in the art, andprovide water repellent properties to treated components. Persons havingordinary skill in the art are familiar with a variety of DWR treatments,any of which may optionally be used on fibers (e.g., on fibers of thefirst or second populations) in connection with the present invention.In some embodiments, fibers used in the inventive insulation (which maybe referred to as DWR-treated fibers or water repellant fibers) havebeen treated with a polymer solution of zirconium acetate, which canimpart durable water repellant properties while minimizing and/oravoiding negative effects on fiber performance. In some embodiments,fibers treated with a durable water repellant are treated with awater-repellant, bacterial-resistant, low friction cured zirconiumacetate finish, such that the fibers have improved driability followingwashing and enhanced handle and resistance to clumping. An example of azirconium acetate solution that may be used as a DWR treatment inconnection with the present invention is disclosed in U.S. Pat. No.4,537,594. In some embodiments, the fiber treated with a durable waterrepellant is treated in a wet bath or dry spraying process. In someembodiments, the treatment comprises a surface energy modificationtechnique, which, as is known in the art, may include, e.g., plasmatreatment. Such treatments or processes are explained in U.S. Pat. Nos.4,869,922, 5,262,208, 5,895,558, 6,416,633, 7,510,632, 8,309,033, and8,298,627.

In some embodiments, synthetic fibers of the first and/or secondpopulations comprise particles or material that is different from thesynthetic material that the synthetic fiber is primarily comprised of.In some embodiments, synthetic fibers of the first and/or secondpopulations comprise up to 15 wt % of particles or material that isdifferent from the synthetic material that the synthetic fiber isprimarily comprised of. For example, in some embodiments, the syntheticfibers comprise 0, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0,1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4,2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8,3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2,5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6,6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0,8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4,9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7,10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9,12.0, 12.1, 12.2, 12.3, 12.4, 12.5, 12.6, 12.7, 12.8, 12.9, 13.0, 13.1,13.2, 13.3, 13.4, 13.5, 13.6, 13.7, 13.8, 13.9, 14.0, 14.1, 14.2, 14.3,14.4, 14.5, 14.6, 14.7, 14.8, 14.9, or 15.0 wt % of particles ormaterial different from the synthetic material that the synthetic fiberis primarily comprised of, including any and all ranges and subrangestherein. In some embodiments, said particles or material is comprisedwithin (e.g., encapsulated within) a polymer matrix that represents thesynthetic material of which the synthetic fiber is primarily comprised.In some embodiments, the synthetic fibers in the fiber mixture compriseaerogel fiber, as described in International Application Publication No.WO/2017/087511. In some embodiments, the synthetic fibers in the fibermixture comprise microcapsules, as described in U.S. ProvisionalApplication No. 62/586,507.

In addition to the bicomponent fibers and optionally the first andsecond populations of synthetic fibers, the flap fiber mixture alsocomprises 5 to 40 wt % synthetic binder fibers (e.g., 5, 6, 7, 8, 9, 10,11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28,29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40 wt %), including anyand all ranges and subranges therein (e.g., 10 to 30 wt %). Generallyspeaking, the binder fibers having a bonding temperature lower than thesoftening temperature of other synthetic polymeric fibers present in theflap fiber mixture.

In some embodiments, the binder fibers have a bonding temperature ofless than or equal to 200° C. In some embodiments, the binder fibershave a bonding temperature of 50 to 200° C., including any and allranges and subranges therein. In some embodiments, the binder fibershave a bonding temperature of 80° C. to 150° C. In some embodiments, thebinder fibers have a bonding temperature of 100° C. to 125° C.

In some embodiments, the binder fibers comprise low-melt polyesterfibers.

In some embodiments, the binder fibers are bicomponent fibers comprisingan exterior and interior (commonly known in the art as a sheath andcore), wherein the exterior comprises a material having a lower meltingpoint than the interior.

The inventive insulation, in some embodiments, has been heat treated soas to melt all or a portion of the binder fibers, thereby forming athermally bonded insulation. Persons having ordinary skill in the artwill understand that, in such embodiments, although “binder fibers” arerecited in the fiber mixture, said fibers may be wholly or partiallymelted fibers, as opposed to binder fibers in their original, pre-heattreatment form.

The binder fibers have a denier of 1.5 to 4.0 denier (e.g., 1.5, 1.6,1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0,3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or 4.0 denier), includingany and all ranges and subranges therein.

The binder fibers have a staple cut length of 38 to 105 mm (e.g., 38,39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56,57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74,75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92,93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, or 105 mm),including any and all ranges and subranges therein.

As discussed above, the composition of the flap fiber mixture makes theflaps of embodiments of the inventive insulation reactive to an externalstimulus. The flap fiber mixture is thus the composition of flaps withinthe insulation (e.g., of flaps 4 depicted in insulation 10 of FIGS. 1and 2).

In some embodiments, the non-flap portion(s) of the insulation (e.g.,non-flap portion 6 depicted in insulation 10 of FIGS. 1 and 2) comprisesa different fiber mixture than the flap fiber mixture (e.g., a fibermixture corresponding to the flap fiber mixture, but excluding thereactive bicomponent fibers discussed above, or even an entirelydifferent fiber mixture). Such embodiments may be formed, for example,using a pre-determined pattern for laying the fibers making up theinsulation. In other embodiments, the non-flap portions comprise anon-flap fiber mixture that is the same as the flap fiber mixture.

In some embodiments, the inventive insulation is non-woven.

In some embodiments, the inventive insulation comprises a singlenon-woven web. In other embodiments, the inventive insulation comprisestwo or more (e.g., 2, 3, 4, etc.) non-woven webs, which are layered.Where a single nonwoven web is used in the insulation, the insulationmay be referred to as a non-layered insulation. Where a plurality (i.e.,2 or more) of nonwoven webs are used, the insulation may be referred toas a layered insulation. Embodiments of the inventive insulation mayalso be referred to as batting.

In some embodiments, the flap fiber mixture and/or non-flap portionfiber mixture additionally comprises other synthetic and/or naturalfibers. For example, in some embodiments, the fiber mixture comprisesone or more members selected from wool, cotton, tencel, kapok(cotton-like fluff obtained from seeds of a Kapok tree, which mayoptionally be further processed before use), flax, animal hair, silk,and down (e.g., duck or goose down).

In some embodiments, the insulation has a thickness of 4 to 30 mm (e.g.,4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22,23, 24, 25, 26, 27, 28, 29, or 30 mm), including any and all ranges andsubranges therein.

In some embodiments, the insulation has a density of 3.0 to 12.0 kg/m³(e.g., 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2,4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6,5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0,7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4,8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8,9.9, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0,11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, or 12.0 kg/m³),including any and all ranges and subranges therein.

Embodiments of the inventive insulation have a first surface parallel toa second surface. For example, the entire top view of insulation 10depicted in FIGS. 1 and 2 is of the first surface. The second surface ofinsulation 10 is not visible, as it is parallel to the first surface,and in contact with a table on which insulation 10 is placed.

In some embodiments, the first surface and/or the second surface of theinsulation comprises a cross-linked resin. This is the case where, forinstance, a cross-linker solution comprising a cross-linker compound hasbeen applied to the first and/or second surface. In various embodiments,the resin is a cross-linked (e.g., via heat treatment) version of thecross-linker solution. In some embodiments, the cross-linked resincomprises a cross-linker that is a cross-linked acrylate (co)polymer. Insome embodiments, the cross-linker solution and/or the cross-linkercompound display softness and hydrophobicity. In some embodiments, thecross-linker compound has a glass transition temperature (Tg) of lessthan 0° C.

In some embodiments, the inventive insulation has a weight of 25 to 200gsm (e.g., 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39,40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57,58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75,76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93,94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108,109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122,123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136,137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, 150,151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164,165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178,179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192,193, 194, 195, 196, 197, 198, 199, or 200 gsm), including any and allranges and subranges therein (e.g., 25 to 100 gsm, 40 to 100 gsm, etc.).

In some embodiments, the inventive insulation has good drape (theinsulation hangs under its own weight). An insulation's drape can have asignificant bearing on qualities such as comfort and aesthetics of anarticle within which the insulation may be used. In some embodiments,the insulation has a drape of 1.5 cm to 5.0 cm (e.g., 1.5, 1.6, 1.7,1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1,3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5,4.6, 4.7, 4.8, 4.9, or 5.0 cm) including any and all ranges andsubranges therein, as measured in accordance with Method ASTM D1388.

In some embodiments, the insulation is in, or is suitable for providingin sheet form (e.g., suitable for use as a rolled good) and has not beenshredded.

In a second aspect, the invention provides an article comprising theinventive insulation according to the first aspect of the invention.Non-limiting examples of such articles include, for example, footwear,outerwear (e.g. outerwear garments such as jackets, pants, etc.),clothing (e.g., socks, under garments, apparel), pillows, pads, sleepingbags, bedding (e.g., quilts, comforters), tents, etc.

In a third aspect, the invention provides a non-exclusive method ofmaking the inventive insulation according to the first aspect of theinvention (or an article according to the second aspect of theinvention), said method comprising:

-   -   forming an intermediate insulation from a fiber mixture, said        intermediate insulation comprising a plurality of flap areas        that comprise the flap fiber mixture discussed in accordance        with the first aspect of the invention;    -   heating the intermediate insulation in excess of the bonding        temperature of the binder fibers in the flap fiber mixture; and    -   forming a plurality of flaps (e.g., via slits) in the        intermediate insulation, thereby creating a plurality of        reactive flaps.

In some embodiments, the insulation is nonwoven insulation comprisingone or more nonwoven web layers. Where the insulation comprises morethan one nonwoven web, the inventive method comprises layering thenonwoven web layers.

Said heating can be performed, for example, using one or more heatingcycles in a standard textile thermal bonding oven.

In some embodiments, the one or more nonwoven web layers comprise, inboth the flap areas and also non-flap areas, the flap fiber mixture.

In some embodiments, the method additionally comprises (e.g., after saidheating), applying to the first surface and/or the second surface of theintermediate batting insulation structure a resin (e.g., a cross-linkedresin as discussed above) Resin-treating one or both of the surfaces ofthe insulation can help to increase stability and integrity of theintermediate batting so as to improve durability and help make thematerial durable enough to withstand downstream processing in slitcutting process.

In some embodiments, the flaps are formed by forming slits, e.g., viacutting. In some embodiments, cutting comprising manual cutting orlaser-cutting using a laser cutting machine. Laser cutting machinesconducive toward use in the textile field are well known to personshaving ordinary skill in the art.

In some non-limiting embodiments, the invention is as described in oneof the following clauses:

Clause 1. Insulation having a plurality of reactive flaps therein, suchthat the insulation comprises the flaps and also non-flap portions,wherein said reactive flaps comprise a flap fiber mixture thatcomprises:

-   -   20-80 wt % bicomponent fibers having a core and a sheath, said        fibers having a denier of 2.0 to 8.0 denier, and a staple cut        length of 38 to 105 mm, wherein said bicomponent fibers are        reactive to an external stimulus, and have a first configuration        in an unactivated state and a second configuration in an        activated state, and wherein the bicomponent fibers can        reversibly transform between the unactivated and activated        states;    -   5-40 wt % synthetic binder fibers having a denier of 1.5 to 4.0        denier and a staple cut length of 38 to 105 mm;    -   0-75 wt % of a first population of synthetic fibers, being        synthetic polymeric fibers having a denier of less than 2.0        denier and a staple cut length of 38 to 105 mm; and    -   0-75 wt % of a second population of synthetic fibers, being        synthetic polymeric fibers having a denier of 4.0 to 10.0 denier        and a staple cut length of 38 to 105 mm.

Clause 2. The insulation according to clause 1, wherein said insulationis non-woven.

Clause 3. The insulation according to clause 1 or clause 2, wherein thefibers of the first population of synthetic fibers are siliconized.

Clause 4. The insulation according to any one of clauses 1 to 3, whereinthe fibers of the second population of synthetic fibers are siliconized.

Clause 5. The insulation according to any one of clauses 1 to 4, whereinthe fibers of the first population of synthetic fibers have a standardcrimp.

Clause 6. The insulation according to any one of clauses 1 to 5, whereinthe fibers of the second population of synthetic fibers have aspring-like crimp.

Clause 7. The insulation according to clause 6, wherein the fibers ofthe second population of synthetic fibers have a helical crimp.

Clause 8. The insulation according to any one of clauses 1 to 7, whereinthe non-flap portions of the insulation comprise a non-flap fibermixture that is the same as the flap fiber mixture (the insulation ismade of the same fiber mixture, for both flap and non-flap portions).

Clause 9. The insulation according to any one of clauses 1 to 8, whereinthe bicomponent fibers comprise 20 to 50 wt % core material and 50 to 80wt % sheath material.

Clause 10. The insulation according to any one of clauses 1 to 9,wherein the core of the bicomponent fibers comprises a non-hygroscopiccore material and the sheath of the bicomponent fibers comprises ahygroscopic sheath material.

Clause 11. The insulation according to any one of clauses 1 to 10,wherein the core of the bicomponent fibers comprises polypropylene andthe sheath comprises nylon.

Clause 12. The insulation according to any one of clauses 1 to 11,wherein the bicomponent fibers comprise 20 to 40 wt % core material and60 to 80 wt % sheath material.

Clause 13. The insulation according to any one of clauses 1 to 12,wherein the core of the bicomponent fibers is an off-center core.

Clause 14. The insulation according to any one of clauses 1 to 13,wherein the second configuration has increased twist as compared to thefirst configuration.

Clause 15. The insulation according to any one of clauses 1 to 14,wherein the bicomponent fibers have a helical crimp.

Clause 16. The insulation according to clause 15, wherein the firstconfiguration is a helix and the second configuration is a helix withrelatively decreased radius and pitch as compared to the firstconfiguration.

Clause 17. The insulation according to any one of clauses 1 to 16,wherein the flap fiber mixture comprises:

-   -   40-80 wt % of the bicomponent fibers;    -   10-40 wt % of the synthetic binder fibers; and    -   5-50 wt % of the first population of synthetic fibers, wherein        said first population of synthetic fibers are siliconized and        have a denier of less than 1.5 denier.

Clause 18. An article comprising the insulation according to any one ofclauses 1 to 17.

Clause 19. The article according to clause 18, wherein said article isselected from footwear, outerwear, clothing, sleeping bags, tents, andbedding.

Clause 20. A method of making the insulation according to any one ofclauses 1 to 17, said method comprising:

-   -   forming an intermediate insulation from a fiber mixture, said        intermediate insulation comprising a plurality of flap areas        that comprise the flap fiber mixture;    -   heating the intermediate insulation in excess of the bonding        temperature of the binder fibers in the flap fiber mixture; and    -   forming a plurality of flaps in the intermediate insulation,        thereby creating a plurality of reactive flaps.

Clause 21. The method according to clause 20, wherein said forming aplurality of flaps in the intermediate insulation compriseslaser-cutting flaps in the intermediate insulation.

EXAMPLES

The invention will now be illustrated, but not limited, by reference tothe specific embodiment described in the following example.

Example 1

An embodiment of the inventive insulation is made as follows:

A fiber mixture is prepared by mixing:

-   -   20% 2.2 Denier×51 MM Low Melt Binder Fiber    -   60% 2.0 Denier×51 MM Bicomponent Adaptive        Fiber—Nylon/Polypropylene    -   20% 1.4 Denier×51 MM Siliconized Fiber w/Standard Crimp        After being mixed/blended, the fiber mixture is then processed        into web form on a traditional carding machine to form a        nonwoven web. The web is then sent through a cross-lapper in        order to obtain the desired weight and thickness. The        cross-lapped webbing is then thermally bonded and is        subsequently sprayed with a resin solution. C-shaped slits are        cut into the material, thereby forming flaps. The final        insulation embodiment is depicted in FIG. 1.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprise” (andany form of comprise, such as “comprises” and “comprising”), “have” (andany form of have, such as “has” and “having”), “include” (and any formof include, such as “includes” and “including”), “contain” (and any formcontain, such as “contains” and “containing”), and any other grammaticalvariant thereof, are open-ended linking verbs. As a result, a method orarticle that “comprises”, “has”, “includes” or “contains” one or moresteps or elements possesses those one or more steps or elements, but isnot limited to possessing only those one or more steps or elements.Likewise, a step of a method or an element of an article that“comprises”, “has”, “includes” or “contains” one or more featurespossesses those one or more features, but is not limited to possessingonly those one or more features.

As used herein, the terms “comprising,” “has,” “including,”“containing,” and other grammatical variants thereof encompass the terms“consisting of” and “consisting essentially of.”

The phrase “consisting essentially of” or grammatical variants thereofwhen used herein are to be taken as specifying the stated features,integers, steps or components but do not preclude the addition of one ormore additional features, integers, steps, components or groups thereofbut only if the additional features, integers, steps, components orgroups thereof do not materially alter the basic and novelcharacteristics of the claimed compositions or methods.

All publications cited in this specification are herein incorporated byreference as if each individual publication were specifically andindividually indicated to be incorporated by reference herein as thoughfully set forth.

Subject matter incorporated by reference is not considered to be analternative to any claim limitations, unless otherwise explicitlyindicated.

Where one or more ranges are referred to throughout this specification,each range is intended to be a shorthand format for presentinginformation, where the range is understood to encompass each discretepoint within the range as if the same were fully set forth herein.

While several aspects and embodiments of the present invention have beendescribed and depicted herein, alternative aspects and embodiments maybe affected by those skilled in the art to accomplish the sameobjectives. Accordingly, this disclosure and the appended claims areintended to cover all such further and alternative aspects andembodiments as fall within the true spirit and scope of the invention.

1. Insulation having a plurality of reactive flaps therein, such thatthe insulation comprises the flaps and also non-flap portions, whereinsaid reactive flaps comprise a flap fiber mixture that comprises: 20-80wt % bicomponent fibers having a core and a sheath, said fibers having adenier of 2.0 to 8.0 denier, and a staple cut length of 38 to 105 mm,wherein said bicomponent fibers are reactive to an external stimulus,and have a first configuration in an unactivated state and a secondconfiguration in an activated state, and wherein the bicomponent fiberscan reversibly transform between the unactivated and activated states;5-40 wt % synthetic binder fibers having a denier of 1.5 to 4.0 denierand a staple cut length of 38 to 105 mm; 0-75 wt % of a first populationof synthetic fibers, being synthetic polymeric fibers having a denier ofless than 2.0 denier and a staple cut length of 38 to 105 mm; and 0-75wt % of a second population of synthetic fibers, being syntheticpolymeric fibers having a denier of 4.0 to 10.0 denier and a staple cutlength of 38 to 105 mm.
 2. The insulation according to claim 1, whereinsaid insulation is non-woven.
 3. The insulation according to claim 1,wherein the fibers of the first population of synthetic fibers aresiliconized.
 4. The insulation according to claim 1, wherein the fibersof the second population of synthetic fibers are siliconized.
 5. Theinsulation according to claim 1, wherein the fibers of the firstpopulation of synthetic fibers have a standard crimp.
 6. The insulationaccording to claim 1, wherein the fibers of the second population ofsynthetic fibers have a spring-like crimp.
 7. The insulation accordingto claim 6, wherein the fibers of the second population of syntheticfibers have a helical crimp.
 8. The insulation according to claim 1,wherein the non-flap portions of the insulation comprise a non-flapfiber mixture that is the same as the flap fiber mixture.
 9. Theinsulation according to claim 1, wherein the bicomponent fibers comprise20 to 50 wt % core material and 50 to 80 wt % sheath material.
 10. Theinsulation according to claim 1, wherein the core of the bicomponentfibers comprises a non-hygroscopic core material and the sheath of thebicomponent fibers comprises a hygroscopic sheath material.
 11. Theinsulation according to claim 1, wherein the core of the bicomponentfibers comprises polypropylene and the sheath comprises nylon.
 12. Theinsulation according to claim 1, wherein the bicomponent fibers comprise20 to 40 wt % core material and 60 to 80 wt % sheath material.
 13. Theinsulation according to claim 1, wherein the core of the bicomponentfibers is an off-center core.
 14. The insulation according to claim 1,wherein the second configuration has increased twist as compared to thefirst configuration.
 15. The insulation according to claim 1, whereinthe bicomponent fibers have a helical crimp.
 16. The insulationaccording to claim 15, wherein the first configuration is a helix andthe second configuration is a helix with relatively decreased radius andpitch as compared to the first configuration.
 17. The insulationaccording to claim 1, wherein the flap fiber mixture comprises: 40-80 wt% of the bicomponent fibers; 10-40 wt % of the synthetic binder fibers;and 5-50 wt % of the first population of synthetic fibers, wherein saidfirst population of synthetic fibers are siliconized and have a denierof less than 1.5 denier.
 18. An article comprising the insulationaccording to claim
 1. 19. The article according to claim 18, whereinsaid article is selected from footwear, outerwear, clothing, sleepingbags, and bedding.
 20. A method of making the insulation according toclaim 1, said method comprising: forming an intermediate insulation froma fiber mixture, said intermediate insulation comprising a plurality offlap areas that comprise the flap fiber mixture; heating theintermediate insulation in excess of the bonding temperature of thebinder fibers in the flap fiber mixture; and forming a plurality offlaps in the intermediate insulation, thereby creating a plurality ofreactive flaps.
 21. The method according to claim 20, wherein saidforming a plurality of flaps in the intermediate insulation compriseslaser-cutting flaps in the intermediate insulation.